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30 Route 18 | Suite 1 | Old Bridge NJ 08857 | Tel: 732-679-2200

INSIGHTS IN AUTOMATION

Monitoring Big Data

The Challenge

 

A pharmaceutical firm needed an environmental monitoring data system.   Their environmental data, collected from multiple distant facilities, covers:

 

Temperature

Humidity

Differential Pressure Readings

 

The system needs to log, report and track up to 120 inputs in each of their storage areas.

 

Our client wanted to fulfill the FDA requirements while being sensitive to implementation costs.  The FDA requirements on electronic data collection cover:

 

• Manufacturing

• Processing

• Packaging

• Storing

• Record keeping

 

These requirements ensure the trustworthiness and security of both the pharmaceutical product and the data regarding it.

Our Contributions

We recommended a SCADA and database interface, Inductive Automation’s Ignition® with an unlimited user license.  Ignition is a web-based application platform.  Primary Systems Inc. also provided:

 

• Pre-installation design

• New Allen-Bradley PLCs

• Programming

• Testing and FAT (Factory Acceptance Testing)

• On-site Commissioning and SAT (Site Acceptance Testing)

Results

The results surpassed  our client’s objectives.

 

The environmental monitoring data system:

 

• Experienced zero downtime during the migration process.

 

• Provides historical data, alarms and audit trail information.  It is accessible by an unlimited number of viewers via the client’s intranet.

 

• Includes an integrated alarming system.  The staff receives email and mobile messages based on established alarm levels, including a pre-alarm warning. The pre-alarm warnings have minimized the number of FDA-reportable alarms.

 

• Is easily expandable.  The client can easily add hardware (sensors, communications and I/O).  The client has already expanded their inputs to include external temperature, dust collection and electrical generators.

 

• Is accessible for remote software support by Primary Systems Inc. This enables:

 

o Quick turnaround for changes and updates

 

o Rapid troubleshooting, if needed

 

 

If monitoring and managing  your history and trending “big data” are a challenge, give us a call.  We are happy to help you find a Solution.

 

 

 

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